Buoyant hose



Jan. 28, 1964 F. M. GALLOWAY ETAL 3,119,415

BUOYANT noss Filed March 9, 1962 2 Sheets-Sheet 2 fi F I l Q g m 1INVENTORS FREDERICK M. GALLOWAY ATTO R N EY United States Patent3,119,415 BUQYANT lltl E Frederick M. Galloway and Richard M. Kerr,Langhorne, Godfrey J. Rittenhouse, Feasterviile, and Robert H. binnamon,Huntingdon Valley, Pa., assignors to H. K. Porter Company, Inc,Pittsburgh, Pa., a corporation of Delaware Filed Mar. 9, 1962, Ser. No.178,6l6 2 Claims. (Cl. 138-133) This invention relates to hose primarilyfor conveying liquids such as petroleum and petroleum products, and isespecially directed to the provision of a buoyant hose resistant to theaction of water and to organisms found therein adapted for carryingliquids between, for example, a ship moored offshore and a shorestation, or between ships afloat, without requiring support from floats,pontoons or the like to prevent the hose from sinking.

Recently developed ships of large size, particularly tankers in excessof 100,000 dead weight tons are unable to moor alongside docks at manyports because of size, insufficient channel depth or other reasons andit has been suggested that buoys anchored offshore and connected bysuitable submarine pipe lines or hoses with shore based facilities beprovided to permit loading and unloading of liquid cargo, fueling withliquid fuel and the like without docking and thus enlarge the usefulnessof such ships and also assist in reducing congestion in existing ports,such buoys comprising a swivel type mooring about which a ship can swingin response to wind, tide or current conditions. For transmittingliquids between the buoy and a ship moored to it, however, it isessential a flexible hose be provided and it has been the practice tosecure floats, pontoons or the like thereto at longitudinally spacedintervals to keep it afloat, as allowing the hose to rest on the bottomin deep water requires too great a length of hose in proportion to thetrue distance involved and may place excessive strains on the endcouplings as well as on those joining sections of the hose.

For most efficient operation of such installations therefore a hose isrequired having inherent buoyancy adequate to cause it to float in freshor sea water while conveying a liquid the density of which may begreater than that of either and it is a principal object of theinvention to provide such hose having the necessary reserve buoyancyeven when filled with a relatively dense fluid.

A further object is to provide a hose in which cellular materials areincorporated but isolated from the hose conduit as well as from itsexternal surroundings whereby air or other gaseous fluid entrapped inthe cellular material 0 compensates for the weight of structuralcomponents of the hose so that when submerged it displaces a volume ofwater larger than that of weight equal to its own, a reserve buoyancy ofthe order of 25% normally being deemed adequate.

Other objects, purposes and advantages of our novel hose will more fullyappear or be understood from the following description of a preferredembodiment of it produced in accordance with the method comprehended bythe invention, reference being had to the accompanydrawings in which:

FIG. 1 is a diagrammatic side View of a ship moored to a buoy as abovedescribed with a hose of the character of those embodying the inventioninterconnecting them for conveyance of liquid from one to the other;

FIG. 2 is an enlarged fragmentary side elevation, with successive layersbroken away to show internal construction, of a piece of our novel hose;

FIG. 3 is a further enlarged fragmentary side elevation, partly brokenaway, of a tubular reinforcing member comprised in the hose;

FIG. 4 is a transverse section on line 44 in FIG. 2;

FIG. 5 is a fragmentary axial section of a portion of the hose wall,showing one manner of attachment of a coupling to the hose end;

FIG. 6 is a greatly enlarged fragmentary axial section of a portion ofthe buoyancy jacket wall in proces of construction, and

FIG. 7 is a fragmentary view corresponding to FIG. 6 but showing thejacket at a later state of construction.

Referring now more particularly to the drawings it will be recognizedthe arrangement illustrated in FIG. 1 is but typical of an environmentin which the invention may find great utility and is not to be deemed aslimiting the field of usefulness of hose constructed in accordancetherewith. Thus the anchored buoy B, ship S moored thereto by a mooringline M and submarine conduits C connecting the buoy with a shore station(not shown) constitute no part of the invention, the latter beingdirected to floating hose H connecting the ship and buoy for transfer ofliquid or semi-liquid material from one to the other.

This hose, shown in greater detail in the subsequent figures, comprisesan inner tube 1 of neoprene or other elastomeric composition resistantto the action of materials transported by the hose, about which aredisposed a plurality of plies 2 (preferably eight in a 12" ID. hose) offabric reinforcing material, which may be nylon cord tire fabricfrictioned with uncured neoprene or other suitable elastomer applied ina manner hereinafter more fully described. Outwardly from the outermostply 2 is a neoprene or other rubber-like composition cushioning layer 3in which is embedded a steel wire 4 formed in a helix coaxial with innertube 1 and reinforcing plies 2 while outside the cushioning layer is afurther plurality of reinforcing plies 5 similarly of neoprenefrictioned nylon the cord fabric as will hereinafter more fully appear.Eight of these plies 5 are desirably employed in a 12 ID. hose, whilefewer may be needed in smaller hoses and more in larger ones; a cover 10of neoprene or the like surrounds the outermost.

Except for omission, as yet, of vulcanizing of its vulcanizablecomponents the hose thus far described is not substantially differentfrom completed ordinary heavy duty discharge hose but the latter, evenin large sizes, is so dense as to have negative buoyancy in water evenwhen containing a liquid substantially less dense than it or whenevacuated, and in the following description of the addition of means forsupplying buoyancy it will be understood that if desired like principlesmay be employed for rendering buoyant an already vulcanized hose.

In accordance with the invention, overlying and surrounding cover 10 isa thick layer 12 of multicellular closed cell sponge rubber havingembedded within it a helical buoyancy and centering tube 13 hereinaftermore fully described, which is arranged in a tight helix coaxial withthe underlying hose components and filled with a flexible closed cellspongy mass 14, preferably a foamedin-place isocyanate foam which ischemically inert to most corrosive or other deteriorating agents likelyto be encountered in marine service while covering and enclosing thesponge rubber layer 12 are two additional neoprene impregnated nyloncord fabric reinforcing plies 15, 1d, the latter enclosed within asmooth cover 17 of neoprene cover stock, the whole being consolidatedinto an integral unit by vulcanizing which cures the elastomericcomponents and seals the body of the hose and its surrounding buoyancyjacket against ingress of deteriorating chemical or biological elementswhile retaining air or gas produced by foaming in the cels of thecellular components.

More specifically with respect to the components of the hose we preferin its manufacture to employ for the fabric reinforcing plies 2 and 5neoprene frictioned tire cord fabric cut on a bias of about 54 to thewarp yarns so the high twist nylon cords forming the warp extend atabout that angle to the hose axis when the fabric is incorporateditherein, the relatively weak and more widely spaced filler yarns ofcourse extending at approximately 90 to the warp yarns and functioningprimarily to hold the latter together during processing since theynormally afford little if any reinforcement to the finished hose.Preferably, however, the angularity of the warp yarns in plies 2 and isalternated between positive and negative angles of about 54 to the hoseaxis so that the warp yarns in each ply define with the warp yarns of anadjacent one an included angle of about 108. This construction en-'ables the plies which, as noted, offer the greatest tensile strength inthe direction of their warp yarns, to reinforce each other wherebystresses tending to separate laterally the warp yarns of any ply arecounteracted by the relatively great strength in the warp yarns of atleast one adjacent ply.

The steel wire 4 reinforcing the inner hose between plies 2 and 5 ispreferably a high tensile strength one of about 7 diameter wound in ahelix so that adjacent convolutions are spaced apart axially of the hoseabout A" in a 12 ID. hose although the wire diameter and the spacing ofits convolutions are not critical and will usually differ in larger orsmaller hoses; near the ends of the hose sections they are preferablysomewhat closer together than elsewhere, as is indicated in FIG. 5.

The buoyancy and centering tube 13 comprises two plies 18, 19 of lightfabric sheeting frictioned with uncured neoprene impregnant and cut on a45 bias between which is disposed a helical carbon steel ribbon 20 aboutA3- .047" in cross section wound in a helix with about 4 betweenconvolutions when a tube of about 2 /z"3" ID. is employed, this sizebeing preferred for 12" ID. hose. As the warp and filler or" the lightsheeting used for this tube are of about equal tensile strength therelative angularity of the warp yarns in the respective plies is not ofgreat importance since they are cut on the bias at about 45 and it issubstantially immaterial whether the warp yarns in one parallel orextend normal to those in the other. The tube, after it is formed butbefore curing of the impregnant of the fabric, is filled with anisocyanate flexible foam, preferably of the type known asfoamed-in-place foams which are created by bringing together in thespace to be occupied liquid ingredients which react together on contactforming a flexible mass of a multiplicity of individual cells, usuallycontaining a gaseous reaction product, which is extremely light inweight (of the order of 1-2 pounds per cubic foot) yet resistant topenetration by water as well as to the action of chemical or biologicalagents of natural occurrence in the envirornent in which the hose is tobe used.

On the other hand the spongy material 12 in which tube 13 is embedded isa low gravity crude rubber milled together with a suitable blowing agentsuch as one containing N,N dinitrosopentamethylene tetramine sold asUnicel ND by E. L. Du Pont de Nemours Co., Wilmington, Delaware, and anactivator such as Retarder W also supplied by said company. Aftermilling, this material is preferably extruded by known means into anelongated strip of triangular cross section which is incorporated in thehose in a manner hereafter explained.

The outer fabric reinforcing plies 15, 16 surrounding the spongy layer12 are preferably nylon tire cord fabric frictioned with uncuredneoprene but in order to enhance the flexibility of the hose as a wholethey are preferably bias cut at a 45 angle and incorporated in the hosewith the warp yarns of the respective plies thus disposed at 90 to eachother and hence at positive and negative angles of 45 respectively tothe hose axis.

Method of Manufacture The hose may be produced as now to be more fullyset forth, and while many of the individual steps are known or will bereadily understood by those skilled in the art they have not so far aswe are aware been practised in combination in the manufacture of buoyantdischarge hose of the character of that contemplated by the invention.

It will be obvious, however, that the hose, especially in sizes such as12'' ID. and larger is necessarily quite heavy and cumbersome, the OD.of 12' ID. hose being about 521.8" and weight per linear foot about 74.0ib. Moreover it is essential to prevent local collapse in service aswhen the hose is bent over the rail of a ship or used as a suction hosethat it have internal rigidity considerably greater than that of mosthose. Hence while the hose is flexible to the extent it can be benttransversely of its axis to a radius about 12 times its internaldiameter it is usually impractical to place it on a reel or the like.Such considerations tend to limit the practical length of individualhose sections and we usually find it most convenient to make them about30' long, with metal or other suitable connectors at the ends so anydesired length may be attained by joining together the couplings of aplurality of such sections.

In their manufacture we employ an appropriate cylindrical mandrel (notshown) of suitable length supported from its ends on a turning lathe orthe like and after the mandrel surface has been coated with a suitableparting compound we apply in the manner usual in the manufacture oflarge size hoses a sheet of calender-ed uncured neoprene to cover theentire surface of the mandrel and subsequently form inner tube 1 of thedesired length, preferably slightly feathering the overlapping edges ofthe sheet to insure a permanent bond being formed during subsequentvulcanizing. Thereafter the inner fabric plies 2 of neoprene frictionedbias cut nylon tire cord fabric are applied, with adjacent edges ofsuccessive sheets overlapping and the joints in successive pliesstaggered longitudinally, the warp yarns in the plies extending as notedalternately at positive and negative angles of about 54 to the mandrelaxis. A filler strip 21 of uncured neoprene is next placed over theoutermost ply 2, the helical reinforcing wire 4 is then wound about thepartially built hose and another like filler strip 22 applied over thewire helix to thereby form and embed the latter in the relatively thick2-part cushion layer 3. Thereafter neoprene frictioned tire cord fabricplies 5 are successively put on with their warp yarns extendingalternately in successive plies at positive and negative angles of about54 to the mandrel axis similarly to plies 2 and over the outer one thecover It) of uncured neoprene to completely enclose the fabric with itsoverlapping edges feathered to insure a good bond.

Next in accordance with our invention a triangular strip 23 (FIG. 6) offoamed rubber, previously mentioned, conforming in cross section to anisosceles triangle about 1%" high and of 1% base is wound helicallyabout the cover It with approximately 1" between adjacent convolutionsthereby forming a helical trough 24 for reception of buoyancy tube 13which is now wound on and seated in said trough, in a series of helicalconvolutions in which ribbon 29 extends in interrelated helices, onerelated to the helically disposed axis of tube 13 and the other to therelatively rectilinear axis of the hose after which an additional strip25 of the triangular foam rubber is placed in inverted position in thespace between the tube convolutions. While we have indicated in FIG. 6an arrange ment in which these components define substantial voids abouttube 13 it will be understood the yielding character of the foamedrubber strip in practice reduces these voids to a minimum preliminary totheir substantial elimination in a succeeding step (FIG. 7) during whichthe foam rubber of the inner and outer strips 23, 25 merges to becomebuoyancy layer 12 to provide a complete enclosure for the tube.

The outer reinforcing plies 15, 16 of neoprene frictioned bias cut nylontire cord fabric are next put on with their warp yarns lyingrespectively at positive and nega tive angles of about 45 as noted andthen enclosed within the outer cover of uncured neoprene sheeting 17preferably about A thick. The entire assembly is then temporarilywrapped under tension in nylon tape (not shown) and subjected tovulcanizing heat as in a curing oven for a time suflicient to cure allthe vulcanizable components, after which it is removed from the oven,cooled, the nylon tape wrapping taken off and the mandrel extracted inany convenient way, thus completing the production of the hose section.

Mention has been made of end couplings for the sections which, however,constitute no part of the invention; obviously they must be accessibleto enable connection between adjacent sections or to suitable fittingsaboard ship or on the buoy and a brief description of the preferredmanner of their incorporation in the hose, and of the finish of thebuoyancy-providing elements near its ends will be of advantage.

Thus as best illustrated in FIG. a sleeve-like end coupling E of metalor other suitable material provided with axially spaced outwardlyprojecting integral annular ribs R is placed on the mandrel adjacenteach end at a spacing corresponding to the length of the hose section tobe made thereon before the inner tube forming sheet is applied so as tooverlie ribs R and a considerable length of the coupling, as do plies 2.After the latter are in place but before the neoprene cushion 3receiving the reinforcing wire 4 is put on, binding ties T of relativelysmall high tensile strength wire are wrapped under tension in compacthelices about the assembly between the ribs R and for an appreciabledistance axially in opposite directions from each of them whereby tube 1and inner fabric reinforcing plies 2 are tightly compacted againstcoupling B after which the construction of the hose proceedssubstantially as hereinabove described until the outer cover 17 has beenapplied.

As indicated in FIG. 5, however, cover proximate the end of the hose isfolded inwardly to engagement with the coupling, thereby providing aseal against access of water to the ends of the fabric plies 2, 5, whilethe rubber foam layer 12 and foam containing buoyance tube 13 embeddedin it, as well as the outermost fabric plies 15, 16 are terminated justshort of alignment with the coupling and the cover 17 turned in overtheir ends to contact with the cover 10 of the hose proper, the end ofcover 17 thus bonding during vulcanizing directly to cover 10 adjacentthe end of the hose.

A 30' hose section of 12'' ID. constructed in accordance with theinvention has excess buoyancy of approximately 990 1b. in sea water whenfilled with sea water, representing in relation to the weight of thehose and its sea water content an excess buoyancy of 26.5%. Thus as thedensity of sea water averages about 1.025 gm./ cu. cm. our hose remainsafloat carrying any liquid not exceeding in density about 1.296 gm./cu.cm. and as very few liquids exceed this density it is contemplated ourhose may be utilized for transporting a great variety of commerciallyuseful liquids besides petroleum and petroleum products and may beutilized economically in many circumstances including permanentinstallations where fluids must be transported across bodies of water,as from one fixed station to another or across marsh lands and the likewhere non-buoyant pipe or hose lines might become irretrievably sunk ina soft bottom.

While we have herein described with considerable particularity oneembodiment of our buoyant hose and the preferred method we have devisedfor making it we do not desire or intend thereby to be limited orconfined thereto in any way as changes and modifications in the form,structure, arrangement and relationship of the several components of thehose itself as well as in the steps utilized in its manufacture willreadily occur to those skilled in the art and may be availed of ifdesired without departing from the spirit and scope of the invention asdefined in the appended claims.

Having thus described our invention, we claim and desire to protect byLetters Patent of the United States:

1. A buoyant hose for conveying fluids between spaced stations across anintervening body of water which comprises an inner tube, a plurality ofplies surrounding the tube and bonded thereto, a layer of elasticcellular material surrounding the outermost of said plies, a helicallydisposed flexible tube embedded in said cellular material, flexiblecellular material in said tube, and a fabric reinforced outer cover ofelastomeric material impervious to water surrounding and enclosing saidfirst named cellular material, said helically disposed flexible tubecomprising a relatively rigid elongated element defining a helix andinner and outer plies embracing said element, the helical convolutionsdefined by said element extending in the hose substantially normal tothe helical convolutions defined therein by the flexible tube.

2. A buoyant hose for conveying fluids between spaced stations across anintervening body of water which comprises an inner tube, a plurality ofplies surrounding the tube and bonded thereto, a helically disposedmetallic element coaxial with the tube interposed between certain ofsaid plies, a layer of elastic cellular material surrounding theoutermost of said plies, a helically disposed flexible tube embedded insaid cellular material, flexible cellular material in said tube, and afabric reinforced outer cover of elastomeric material impervious towater surrounding and enclosing said first named cellular material, saidhelically disposed flexible tube comprising a relatively rigid elongatedelement defining a helix and inner and outer plies embracing saidelement, the helical convolutions defined by said element extending inthe hose substantially normal to the helical convolutions definedtherein by the flexible tube.

References Cited in the file of this patent UNITED STATES PATENTS967,360 Funke Aug. 16, 1910 1,970,513 Knowland Aug. 14, 1934 2,131,343Cordiano et a1 Sept. 27, 1938 2,516,864 Gilmore et al. Aug. 1, 19502,722,263 Beare et al Nov. 1, 1955 2,742,931 De Ganahl Apr. 24, 19562,862,524 Smith Dec. 2, 1958 2,879,803 Francois Mar. 31, 1959 2,919,721Isenberg Jan. 5, 1960 3,047,026 Kahn July 31, 1962 FOREIGN PATENTS1,240,554 France Aug. 1, 1960

1. A BUOYANT HOSE FOR CONVEYING FLUIDS BETWEEN SPACED STATIONS ACROSS ANINTERVENING BODY OF WATER WHICH COMPRISES AN INNER TUBE, A PLURALITY OFPILES SURROUNDING THE TUBE AND BONDED THERETO, A LAYER OF ELASTICCELLULAR MATERIAL SURROUNDING THE OUTERMOST OF SAID PLIES, A HELICALLYDISPOSED FLEXIBLE TUBE EMBEDDED IN SAID CELLULAR MATERIAL, FELXIBLECELLULAR MATERIAL IN SAID TUBE, AND A FABRIC REINFORCED OUTER COVER OFELASTOMERIC MATERIAL IMPREVIOUS TO WATER SURROUNDING THE ENCLOSING SAIDFIRST NAMED CELLUAND INNER AND OUTER PILES EMBRACING SAID ELEMENT, THEHELICAL CONVOLUTIONS DEFINED BY SAID ELEMENT EXTENDING IN THE HOSESUBSTANTIALLY NORMAL TO THE HELICAL CONVOLUTIONS DEFINED THEREIN BY THEFLEXIBLE TUBE.